IAME EASY-KART 2003 Assembly Instructions And User'S Manual Download

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MAN-028

15-

TROUBLESHOOTING

Below are some common faults, their probable causes and suggested remedy:

FAULTS PROBABLE

CAUSE REMEDY

Starter will not crank when
pushing the start button.

Bad connections on starter cables. Check and tighten

Bad grounding

Check connections and tighten

Damaged cables

Replace

Battery connection loose

Check and tighten

Battery discharged

Recharge battery

Starter failure

Overhaul starter

Power Pack internal failure
(connectors)

Apply to Authorized Service Center

Starter cranks but engine won’t
start

Bad cable connections

Check connectors (3 and 4 ways)

Bad H.T. coil connection or coil
failure

Check/Replace

Bad H.T. coil grounding

Check and tighten (2 grounds)

Power pack internal cable bad
connection

Apply to Authorized Service center

Wet spark plug

Replace

Malfunction on induction system

Check status and connections on
fuel pipe

Replace gaskets and membranes
on carburetor

Check reed petals (Reed engine).
Replace if necessary.

Check pressure tube (Piston Port
engine) replace if necessary.

Engine starts when the start
bottom is pressed but it stops
when bottom is released.

Bad cable connections

Check stator connector (4 ways).

Bad connections on Power-Pack
internal cables

Apply to Authorized Service Center

Bad carburetor adjustment

(I screw)

Check carburetor adjustment (see
par. 5)

The starter cranks after having
released the start button

Battery discharged (starter relay
does not disconnect).

Disconnect the positive terminal on
battery and charge battery.

Rough idle

Bad carburetor adjustment

(L Screw)

Check carburetor adjustment (see
par. 5)

Drop in engine performance

Bad compression

Check piston

Bad carburetor adjustment

Check carburetor adjustment (see
par. 5)

Insufficient gas flow

Check gasoline flow lines

Dirty inlet silencer

Check and clean

Burning smell, smoke

Overheating of clutch

Check clutch (Par. 11)

Clutch engages at too high
RPMs

Excessive wear of friction material Check clutch (Par. 11)

Exhaust too noisy

Flexible damaged

Check and replace if necessary

Springs damaged or lost

Insulating strap damaged or lost.

Damaged exhaust header

Summary of Contents for EASY-KART 2003

Page 1: ...MAN 028 EASY KART ENGINES 2003 ASSEMBLY INSTRUCTIONS and USER MANUAL ...

Page 2: ...ion and connection of the power pack box 3 7 Electrical connections on the engine 3 8 Installation of the intake silencer 3 9 Install the exhaust 4 GASOLINE and OIL 5 Carburetor Adjustment guide 6 Starting and stopping the engine 7 Engine break in 8 Inlet silencer 9 Exhaust system 10 Centrifugal clutch 11 Instructions for the assembly disassembly of the clutch 12 Battery 13 Spark plug and thermal ...

Page 3: ... liner is made of centrifugated cast iron machined from the full to guarantee the best possible stability The head is separated from the cylinder and secured by studs The crankshaft is built up and supported by two ball bearings The crankshaft is of steel alloy hardened and tempered as is the connecting rod which runs on roller bearings The igniton includes a 4 pole stator rotor with integral pick...

Page 4: ...ter and has an all position mounting The battery 12 V 7 2Ah is a sealed type without maintenance battery and is supplied already preassembled in the battery and Power Pack support box which can be easily adapted to all existing chassis The exhaust included in the supply is already tuned for the best possible performance ...

Page 5: ... standard on all engines Ignition Digital 4 poles with internal rotor Battery charge With integral generator Electric start 12V 0 30 Kw 12V 0 15 Kw on the 62cc only Clutch Automatic dry centrifugal 2 OPERATIONAL LIMITS Max RPM 12500 RPM on 62cc 15500 RPM on 100 125cc ATTENTION Never exceed the above limits No obligation of IAME exists in case the above limits are exceeded 3 CHARACTERISTICS VALID F...

Page 6: ... Fiber Strip 1 1 Exhaut Header 1 1 Exhaust Muffler 1 1 INDUCTION Tillotson Carburetor 1 1 Intake Silencer 1 1 Intake Silencer Support 1 1 Pressure Fitting Tube 1 Accelerator Cable Bracket 1 1 ELECTRICAL Battery 12 V 1 1 Battery Support 1 1 Battery Strap 1 1 Battery Clamps 2 2 Power Pack Box with Harness 1 1 Plastic Fixing Clamps 8 8 NGK BR 10 EG Spark Plug 1 1 Spark Plug Cap 1 1 MISCELLANEOUS Addi...

Page 7: ...ter see fig The number normally includes 2 letters EK followed by 4 digits Other numbers stamped on the crankcase or other surfaces of the motor refer to various manufacturing processes and do not identify the motor NOTE In case of need for spares and when contacting the IAME Support Centers please always refer to the Motor Identification Number and to the motor model ...

Page 8: ...TH THE EXHAUST GASKET AND NUTS ALREADY INSERTED WHEN THE SHIPMENT IS MADE AN EXHAUST STIFFENER IS INSERTED TO PROTECT THE INTERNAL PARTS 3 1 1 REMOVE THE TWO NUTS AND THE EXHAUST STIFFENER 3 1 2 MAKE SURE THE EXHAUST GASKET IS IN SEAT AND INSTALL THE EXHAUST HEADER SEE FIG 1 3 1 3 INSTALL THE TWO 8mm WASHERS SUGGESTION EVENTUALLY PUT THE ENGINE IN HORIZONTAL POSITION AND DRIVE THE WASHERS WITH A S...

Page 9: ...3 2 PREPARATION AND INSTALLATION OF THE MOTOR MOUNT 3 2 1 DRILL 4 HOLES DIAM 8 5mm IN THE MOTOR MOUNT IN CASE THE SUPPLY INCLUDES THE ADDITIONAL MOTOR MOUNT MOTOR MOUNT HORIZONTAL VIEW MOTOR MOUNT HORIZONTAL VIEW ...

Page 10: ... SURE TO USE M8 ALLEN SCREWS WITH A LENGHT SUCH AS TO ENGAGE IN THE CRANKCASE A THREADED PORTION LENGHT OF APPR 18mm THE SCREW MUST PROTRUDE FROM THE PLATE FOR APPR 18mm SEE FIG 4 AND DRAW PAG 7 4 ALLEN SCREWS M8 TORQUE AT 22 24 Nm 6 mm ALLEN WRENCH INSTALL THE CARBURETOR 3 3 3 3 1 INSTALL THE GAS CABLE CLAMP ON THE SUPPORT SEE FIG 5 12 POINT WRENCH 10mm Fig 3 Fig 4 Fig 5 ...

Page 11: ...O SCREWS SEE FIG 7 3 3 4 INSTALL THE INTAKE SUPPORT 2 SCREWS M5 X10 SEE FIG 8 3 mm ALLEN WRENCH 3 3 5 INSTALL THE CARBURETOR REED VALVE ENGINE SEE FIGG 9 10 REMOVE THE TWO M6 NUTS FROM THE INLET MANIFOLD REMOVE THE PLASTIC PLUG FROM THE INLET MANIFOLD ATTENTION MAKE SURE THAT THE PRESSURE HOLE ON THE GASKET IS NOT PLUGGED 10mm OPEN WRENCH Fig 6 Fig 7 Fig 8 Fig 9 ...

Page 12: ...E THE 2 NUTS M6 REMOVE THE PLASTIC PLUG LEAVE ONE CARB GASKET ON THE ENGINE AND INSTALL IN THE ORDER SEE FIG 11 N 1 PLASTIC SPACER N 1 CARB GASKET CARBURETOR N 2 WASHERS N 2 NUTS M6 TORQUE AT 6 10 Nm CONNECT THE PRESSURE HOSE BOTH ON THE CRANKCASE AND ON THE CARB FITTINGS SEE FIG 12 3 4 INSTALL THE ENGINE ON THE CHASSIS 3 4 1 POSITION THE ENGINE ON THE 2 OUTSIDE MAIN RAILS AND FIX THE MOTOR MOUNT ...

Page 13: ...PROCKET SEE FIG 14 3 4 3 INSTALL THE CHAIN PITCH 7 775 SEE FIG 15 3 4 4 MOVE THE ENGINE ON THE RAILS AND OPTIMIZE THE CHAIN TENSION ATTENTION THE PLAY OF THE CHAIN MUST BE APPR 15mm MEASURED IN THE SHOWN POINT SEE FIG 16 3 4 5 TORQUE THE CLAMP SCREWS Fig 14 Fig 15 Fig 16 15mm ...

Page 14: ...E FIG 18 TORQUE THE 3 SCREWS AT 8 10 Nm ATTENTION ALWAYS MAKE SURE THAT THE GROUND CABLE ALWAYS CONNECTS THE COIL WITH THE ENGINE AN INADEQUATE GROUNDING COULD DAMAGE THE IGNITION BEYOND REPAIR THE POSITION OF THE H T COIL HAS BEEN CHOSEN TO BE AS FAR AS POSSIBLE FROM THE EXHAUST AS THE EXCESSIVE HEAT COULD DAMAGE THE COIL BEYOND REPAIR 5mm ALLEN Fig 17 Fig 18 ...

Page 15: ...ACT THE BATTERY FROM THE SUPPORT AFTER HAVING UNLACED THE BATTERY STRAP SEE FIG 19 3 6 2 POSITION THE SUPPORT CLAMPS ON THE OUTSIDE RAIL BRAKE SIDE AT THE HEIGHT OF THE SEAT FIX THE CLAMPS BY HAND WITH 2 SCREWS M6 X 25 SEE FIG 20 3 6 3 POSITION THE BATTERY SUPPORT BOX ON THE CLAMPS MATCHING THE ATTACHMENT HOLES SEE FIG 21 FIX THE BOX WITH TWO SCREWS M6 X 10 MOVE THE BOX WITH THE 2 CLAMPS TO THE MO...

Page 16: ...HORT CIRCUIT THE BATTERY TERMINALS AS BATTERY COULD BE DAMAGED BEYOND REPAIR ELECTRICAL CONNECTIONS ON THE ENGINE 3 7 3 7 1 GROUND THE POWER PACK ATTENTION AN INADEQUATE GROUNDING OF THE POWER PACK BOX COULD DAMAGE THE BOX BEYOND REPAIR MAKE SURE TO CAREFULLY FOLLOW THE UNDER SHOWN INSTRUCTIONS 3 7 2 POSITION THE HARNESS FROM THE POWER PACK BOX ALONG THE CENTRAL RAIL UNDERNEATH THE SEAT AND TIGHTE...

Page 17: ...ESS FROM THE POWER PACK BOX WITH THE TERMINALS ON THE CABLES FROM THE IGNITION SEE FIG 26 27 ATTENTION MAKE SURE THAT THE FIXING TONGUES ARE PROPERLY INSERTED TO GUARANTEE THE BEST POSSIBLE CONNECTION OF THE TERMINALS 3 7 5 CONNECT THE CABLE TERMINAL SINGLE FROM THE POWER PACK WITH THE CABLE TERMINAL ALREADY CONNECTED TO THE STARTER SEE FIG 28 ATTENTION MAKE SURE THAT THE FIXING TONGUE IS PROPERLY...

Page 18: ...ITH A ROTATING PART AS IT COULD BE DAMAGED BEYOND REPAIR 3 7 7 CONNECT THE COIL CABLE FROM THE POWER PACK TO THE TERMINAL ON THE COIL SEE FIG 31 SUGGESTION SEAL THE TERMINAL ON THE COIL WITH PLASTIC TAPE TO AVOID THAT EVENTUAL VIBRATIONS MIGHT DISCONNECT THE TERMINAL 3 7 8 INSERT THE SPARK PLUG CABLE THROUGH THE SUPPORT SPRING ON THE CYLINDER SEE FIG 32 Fig 29 Fig 30 Fig 31 Fig 32 ...

Page 19: ... INSTALL THE SPARK PLUG AND THE CAP OVER THE SPARK PLUG INSTALL THE SPARK PLUG INSTALL THE SPARK PLUG CAP MAKING SURE THAT THE SPRING IN THE CAP IS WELL INSERTED IN THE SPARK PLUG 3 8 INSTALL THE INTAKE SILENCER MAKE SURE THAT THE FILTER HAS THE INLET HOLES TOWARDS THE UPPER SIDE FIX THE FILTER ON THE CARB WITH A STEEL CLAMP AND THE FILTER TO THE CHASSIS SIDE RAILS WITH PLASTIC CLAMPS SEE FIG 35 3...

Page 20: ...IDEAL LENGHT OF THE EXHAUST 3 9 1 INSTALL THE FLEXIBLE L 65mm FLEXIBLE COMPLETELY CLOSED AND THE EXHAUST HEADER SEE FIG 37 AND CONNECT THE EXHAUST 3 9 2 INSTALL THE FIBER STRIP AROUND THE FLEXIBLE AND FIX WITH THE 3 SPRINGS SEE FIG 38 THE ENGINE IS READY TO BE STARTED Fig 37 Fig 38 ...

Page 21: ...e piston and the head Our experience dictates use of oils such as Shell Advance Racing M ELF HTX 909 ERG K KART 2T CORSE ERG K KART FORMULA Once the fuel tank is filled make sure that gasoline reaches the carburetor before starting the engine Never use the electric starter to suck the gasoline as this would discharge the battery SUGGESTION Disconnect the plastic tube on the carb and the vent tube ...

Page 22: ...RPM is too high adjust I counterclockwise to reduce RPM until the clutch is disengaged Allow engine to heat up for 2 3 minutes Accelerate engine if acceleration is bad then the low speed mixture screw L is either set too lean or too rich 1 Adjust L 1 8 turn counter clockwise reset I and accelerate If acceleration improves but not enough then repeat step 1 until acceleration is satisfactory If acce...

Page 23: ...eplacing jet place jet in threaded orifice and carefully turn clockwise until threads are engaged Using a light hand pressure screw jet in fully until it touches the sealing seat Then secure jet using a medium hand pressure 5 Lb In or 0 565 Nm if using a torque screw driver Over torqueing will distort sealing seat and brass jet 4 Replace sealing screw and gasket turning in a clockwise direction ag...

Page 24: ... with the water proof plastic cover as otherwise water by entering the box could damage the circuits beyond repair When weather is good remove the cover as the eventual condensate might damage the circuits 7 ENGINE BREAK IN The break in of the engine must be performed following a few fundamental rules 1 Adjust the carburetion Start with an adjustment on the rich side 2 Warm the engine gradually fo...

Page 25: ...ged Replace if necessary ATTENTION In case the flexible is damaged metallic particles could be sucked in the engine and cause a seizure Always make sure that the springs are well hooked and in place In case of breakage replace the broken spring Never race the kart without the 3 springs in place as otherwise the exhaust pipe could vibrate beyond control Every 10 15 hours open the pipe end and make ...

Page 26: ...ce the engine is started avoid useless accelerations which can overheat and deteriorate the clutch Oil the chain before each tests after each race or test check the engine sprocket Replace if necessary A bad alignment of the engine sprocket with the axle sprocket or the lack of oil will damage the engine sprocket Check the clutch Every 5 hours of use When metallic noises are heard inside the clutc...

Page 27: ...ENTION The following operations can be performed by a skilled mechanic under the conditions to have available the dedicated tools shown on the text otherwise it is necessary to apply to an Authorized Service Center Refer to the following drawing during the operations A A A 1 2 3 4 5 6 7 8 9 10 A A A 11 12 1 Drum nut 5 Sprocket 9 Cone safety washer 2 External washer 6 Clutch drum 10 Clutch body 3 R...

Page 28: ...the starter ring Clutch assembly 1 Install the starter ring on the clutch body by matching the 3 holes and the dragging pin 3 screws M6 ATTENTION make sure to always install the Ø 7 mm dragging pin as otherwise the eventual kick backs could break the screws 10 mm socket Torque at 10 Nm Apply Loctite on the threads 2 Insert key on shaft 3 Install clutch body and the cone safety washer 4 Install the...

Page 29: ...ttery before use ATTENTION Always connect the negative terminal before and the positive terminal after Always disconnect the battery in opposite order Recharge the battery at least once every 6 months Never put the battery in contact with solvents gasolines oils plastifiers or rags containing such elements The external case of the battery could be damaged Never press or bend or overheat by welding...

Page 30: ...ate the same final look which can also be achieved with a hot or cold sparkplug See table An excessively warm sparkplug shows the symptoms listed aside ATTENTION Always use a warmer than standard spark plug with cold or rainy climates Extremely clear color porous lock and calcification of the electrodes and of the internal insulation Irregularities in the ignition preignition and detonation with t...

Page 31: ...chain Battery Check status and charge Cables and connectors Check status and connections Grounding of engine and Power Pack Check status and connections Engine mount and clamps Check torques After use Battery Disconnect Chain Check status and oil chain Engine External cleaning Bendix assembly Remove cover see fig and clean internally Every 5 10 hours Exhaust muffler Remove muffler end clean Inlet ...

Page 32: ...ne Replace if necessary Check pressure tube Piston Port engine replace if necessary Engine starts when the start bottom is pressed but it stops when bottom is released Bad cable connections Check stator connector 4 ways Bad connections on Power Pack internal cables Apply to Authorized Service Center Bad carburetor adjustment I screw Check carburetor adjustment see par 5 The starter cranks after ha...

Page 33: ... preserved as follows Disconnect the battery and charge it periodically see Par 12 Disconnect carburetor and clean it Seal with tape the engine inlet and exhaust The external of the engine must be cleaned Spray with protective oil the steel parts subject to oxidation Keep the engine in a dry ambient ...

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